User Manual

ManualsBrandsRockwell Automation ManualsEquipment20P PowerFlex DC Drive - Frame A Pulse Transformer Circuit Board

Table Of Contents

Installation Instructions

PowerFlex

DC Drive - Frame A Pulse

Transformer Circuit Board

What This Kit Includes

• Pulse Transformer circuit board

• Six screws with washers

• 6 gate lead cables with connectors (for non-regenerative drives only)

• 12 gate lead cables with connectors (for regenerative drives only)

• Cables for connectors X3 (2 pin) and XP (34 pin)

• Cables for connector X4 (for drives with a fan only)

• Plug-in terminal block with 1k ohm resistor @ terminals 78-79

• Isolation sheet

• Flathead screwdriver for terminal block connections

• Static strap

Tools That You Need

• Phillips

screwdriver

• Flathead screwdriver

• Nut driver or wrench for hex stand-offs

• Multimeter (capable of reading to a thousandth of an Ohm)

• Wire Cutter

Phillips

is a registered trademark of Phillips Screw Company.

ATTENTION: Only qualified personnel familiar with DC

drives and associated machinery should plan or implement the

installation, start-up and subsequent maintenance of the system.

Failure to comply may result in personal injury and/or equipment

damage.

ATTENTION: To avoid an electric shock hazard, ensure that all

power to the drive has been removed before performing the

following.

ATTENTION: This drive contains ESD (Electrostatic

Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or

repairing this assembly. Component damage may result if ESD

control procedures are not followed. If you are not familiar with

static control procedures, reference A-B publication 8000-4.5.2,

“Guarding Against Electrostatic Damage” or any other

applicable ESD protection handbook.

Summary of content (20 pages)

PAGE 1
Installation Instructions PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board ATTENTION: Only qualified personnel familiar with DC drives and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: To avoid an electric shock hazard, ensure that all power to the drive has been removed before performing the following.
PAGE 2
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board What You Need to Do To install the Pulse Transformer board: ❐ Step 1: ❐ Step 2: ❐ Step 3: ❐ Step 4: ❐ Step 5: ❐ Step 6: ❐ Step 7: ❐ Step 8: Step 1: Remove Power from the Drive Remove power from the drive Remove the protective covers Remove the Control EMI shield and Control board Remove the Pulse Transformer and Switching Power Supply boards Configure the new Pulse Transformer board Install the new Pulse Transformer board and existing Swit
PAGE 3
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Step 2: Remove the Protective Covers 3 1. Disconnect the DPI cable from the HIM assembly (if present). 2. Remove the screws that secure the bottom cover to the drive, then slide the cover down and off the drive chassis. = Disconnect DPI cable Tightening torque: 1.5 N•m (13.3.lb•in) 3. Press in on the sides at the bottom edge of the top cover and at the same time pull the cover toward you to pull it partially off the drive chassis. 4.
PAGE 4
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 5. Disconnect the HIM Communication cable from the connector on the upper right corner of the Control board and set the cover aside. Pull tabs out to disconnect cable.
PAGE 5
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Step 3: Remove the Control EMI Shield and Control Board 5 1. Carefully disconnect the cables from connectors XFCD, XA and XR on the Control board. 2.
PAGE 6
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 3. Remove the five screws that secure the ground wire (in the lower left corner) and Control EMI shield to the chassis and slide the Control EMI shield and Control board up and out of the drive. Important: Be careful when removing the EMI shield not to pull free any of the gate leads or other cables on the Pulse Transformer circuit board below the EMI shield.
PAGE 7
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 7 1. Remove the slotted air flow plate from the top of the drive: – For 38A and 55A drives @ 230V AC input and 35A, 45A, and 52A drives @ 460V AC input, remove the four screws that secure the slotted air flow plate to the top of the drive, remove the fan cable from connector XV on the Switching Power Supply board and remove the plate and connected fan.
PAGE 8
T1 KGO1 T4 X4 KGO2 T2 TO2 XSW1 KG2 KGO5 XY KG5 T5 TO5 XR XSW KGO3 T3 TO3 TR2 XP FIR1-XX rev. “Q” and higher TO4 KGO4 KG1 KG4 TO1 XCD_IO X3 T6 S4 1 XTA 1 78 79 35 36 75 76 U2 V2 KG3 KG6 KGO6 TO6 TR1 S3 U C V W KG1 K G T1 KG01 K G C T01 U V K G T4 K G KG04 T04 KG4 W 1 K G T2 1 K G KG02 X4 XSW1 T02 1 1 2 KG5 K G 6 1 XP K G T3 KG03 T03 TR2 KG3 XR K G KG05 T5 T05 1 0V1 XSW XY 1 FIR1-XX rev.
PAGE 9
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 9 Important: Mark all connections and wires before removal to avoid incorrect wiring during reassembly. 2. Remove the plug-in control power terminal block from the Pulse Transformer circuit board. Remove plug-in terminal block 3. Remove the cables from connectors X3, X4 and XP on the Pulse Transformer board. Note: Connector X4 contains a jumper for drives without a fan - leave in place. Remove cables from X3, X4 and XP 4.
PAGE 10
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 5. Remove the appropriate gate leads: – For regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and KG1…KG6 and push each lead through the appropriate opening in the board. – For non-regenerative drives, remove each pair of (orange and yellow) gate lead cables from connectors KG01…KG06 and push each lead through the appropriate opening in the board.
PAGE 11
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 11 7. Remove the six screws that secure the bottom of the Pulse Transformer board to the drive and, while lifting up slightly on the board, slide it toward the top of the drive and out of the chassis. Important: The cables from connectors X4 and XTA must slide through the openings in the board as it is lifted out of the drive chassis. Take care not to damage these cables and connectors.
PAGE 12
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 8. Remove the cable from connector XUV on the Switching Power Supply board. Remove cable at XUV Switching Power Supply board on back of Pulse Transformer board. 9. Remove the five screws from the Pulse Transformer board that secure the stand-offs connected to the Switching Power Supply board and remove the Switching Power Supply board from the back of the Pulse Transformer board.
PAGE 13
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 13 Step 5: Configure the New The Pulse Transformer circuit board must be configured to match the drive size (armature output current and HP rating). The steps required to complete Pulse Transformer Board the configuration are different based on the revision code of the board. See either, Pulse Transformer Board FIR1-XX Rev. “P” and Lower below, or Pulse Transformer Board FIR1-XX Rev. “Q” and Higher on page 17.
PAGE 14
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Sizing Resistor Configuration Table A and Table B below indicate the value of the designated resistor (R1…R5) when left in place on the Pulse Transformer board, or indicate “Remove” when the resistor should be cut off and removed from the board. “–” in a cell in the tables below indicates that this resistor is not contained on the Pulse Transformer board for the designated drive size.
PAGE 15
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 15 2. Connect the leads of a multimeter to pins 13 and 14 of connector XR on the Pulse Transformer circuit board (polarity is not important) and, using the TA potentiometer on the lower right corner of the Pulse Transformer circuit board, set the total resistance (RTA) to the appropriate value as indicated in Table C or Table D in the Total Resistance Values section on page 16. = 2 . . . . . . . . . . . . . 14 . . . . . . . . . . . . . . . .
PAGE 16
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Total Resistance Values Table C 230V AC Input Drives Drive Current Rating Code 7P0 9P0 012 020 029 038 055 073 093 110 DC Amps 7 9 12 20 29 38 55 73 93 110 AC Line Amps 5.7 7.4 9.8 16 24 31 45 60 76 90 HP 1.5 2 3 5 7.5 10 15 20 25 30 Set RTA Value Using TA Potentiometer (Ohms) 34.971 45.333 34 61.2 42.207 32.211 22.255 16.767 13.161 11.
PAGE 17
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board 17 Pulse Transformer Board FIR1-XX Rev. “Q” and Higher Set DIP switches S3 and S4, located on the Pulse Transformer board (see Figure 1 on page 8 for location), to the correct settings based on the appropriate table below. Important: A blank cell below a switch in Tables E and F below indicate that the setting is “OFF”.
PAGE 18
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Step 6: Install the New Pulse Transformer Board and Existing Switching Power Supply Board 1. Install the new Pulse Transformer board and existing Switching Power Supply board in reverse order of removal as detailed in Step 4: Remove the Pulse Transformer and Switching Power Supply Boards on page 6. 2. Install the new Isolation sheet (if present) before installing the Pulse Transformer and Switching Power Supply boards.
PAGE 19
PowerFlex® DC Drive - Frame A Pulse Transformer Circuit Board Step 8: Replace the Protective Covers and Documenting the Change 19 1. Replace the protective covers in the reverse order of removal as described in Step 2: Remove the Protective Covers on page 3. 2. Install the DPI cable (if present). 3. Record the installation of the new Pulse Transformer board and date of installation on the Field Installed Option label on the side of the drive (as shown below).
PAGE 20
1S7A04 www.rockwellautomation.com Power, Control and Information Solutions Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.